Methods and apparatuses for making elastomeric laminates with elastic strands

ABSTRACT

The present disclosure relates to methods for making elastomeric laminates that may be used as components of absorbent articles. In particular, discrete mechanical bonds are applied to a first substrate and a second substrate to secure elastic strands therebetween, wherein the discrete bonds are arranged intermittently along the machine direction. During the bonding process, heat and pressure are applied to the first substrate and the second substrate such that malleable materials of the first and second substrates deform to completely surround an outer perimeter of a discrete length of the stretched elastic strand. After removing the heat and pressure from the first and second substrates, the malleable materials harden to define a bond conforming with a cross sectional shape defined by the outer perimeter of the stretched elastic strand.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.15/833,057, filed on Dec. 6, 2017, now U.S. Pat. No. 11,147,717, whichclaims the benefit of U.S. Provisional Application Nos. 62/436,589,filed on Dec. 20, 2016; 62/483,965, filed on Apr. 11, 2017; 62/553,538,filed on Sep. 1, 2017; 62/553,149, filed on Sep. 1, 2017; 62/553,171,filed on Sep. 1, 2017; and 62/581,278, filed on Nov. 3, 2017, theentireties of which are all incorporated by reference herein.

FIELD OF THE INVENTION

The present disclosure relates to methods for manufacturing absorbentarticles, and more particularly, to apparatuses and methods for makingelastomeric laminates that may be used as components of absorbentarticles.

BACKGROUND OF THE INVENTION

Along an assembly line, various types of articles, such as for example,diapers and other absorbent articles, may be assembled by addingcomponents to and/or otherwise modifying an advancing, continuous web ofmaterial. For example, in some processes, advancing webs of material arecombined with other advancing webs of material. In other examples,individual components created from advancing webs of material arecombined with advancing webs of material, which in turn, are thencombined with other advancing webs of material. In some cases,individual components created from an advancing web or webs are combinedwith other individual components created from other advancing webs. Websof material and component parts used to manufacture diapers may include:backsheets, topsheets, leg cuffs, waist bands, absorbent corecomponents, front and/or back ears, fastening components, and varioustypes of elastic webs and components such as leg elastics, barrier legcuff elastics, stretch side panels, and waist elastics. Once the desiredcomponent parts are assembled, the advancing web(s) and component partsare subjected to a final knife cut to separate the web(s) into discretediapers or other absorbent articles.

Some absorbent articles have components that include elastomericlaminates. Such elastomeric laminates may include an elastic materialbonded to one or more nonwovens. The elastic material may include anelastic film and/or elastic strands. In some laminates, a plurality ofelastic strands are joined to a nonwoven while the plurality of strandsare in a stretched condition so that when the elastic strands relax, thenonwoven gathers between the locations where the nonwoven is bonded tothe elastic strands, and in turn, forms corrugations. The resultingelastomeric laminate is stretchable to the extent that the corrugationsallow the elastic strands to elongate.

In some assembly processes, stretched elastic strands may be advanced ina machine direction and are adhered between two advancing substrates,wherein the stretched elastic strands are spaced apart from each otherin a cross direction. Some assembly processes are also configured withseveral elastic strands that are very closely spaced apart from eachother in the cross direction. In some configurations, close crossdirectional spacing between elastic strands can be achieved by drawingelastic strands from windings that have been stacked in the crossdirection on a beam. For example, various textile manufacturers mayutilize beam elastics and associated handling equipment, such asavailable from Karl Mayer Corporation. However, problems can beencountered in manufacturing processes when drawing elastic strandsstacked on a beam.

For example, relative low decitex elastic strands supplied on a beam mayinclude a coating, sometimes referred to as a yarn finish or spinfinish, to help prevent the elastics strands from adhering tothemselves, each other, and/or downstream handling equipment. Whenconstructing absorbent articles, hot melt adhesives are often used toadhere stretched elastic stands to advancing substrates to createelastic laminates. However, hot melt adhesives used to bond stretchedelastic strands to substrates when constructing absorbent articles maynot adhere well to strands having a spin finish. As such, increasedamounts of adhesive may be required to adequately adhere the stretchedelastic strands to the substrates than would otherwise be required forelastic stands without a spin finish. In turn, relatively larger amountsof adhesives required to bond the elastic strands to the substrates mayhave a negative impact on aspects of the resulting product, such as withrespect to costs, functionality, and aesthetics.

In an attempt to overcome the aforementioned problems associated withadhesives, some assembly processes may be configured to apply mechanicalbonds with heat and pressure to trap the stretched elastic strandsbetween two substrates. Such mechanical bonds may be created, forexample, by advancing the substrates and elastic strands between anultrasonic horn and anvil. However, the heat and pressure from the anviland horn may also sever the elastic strands. As such, grooves may beprovided in the horn or anvil for the elastic strands to nest in and toshield the elastic strands from pressure and prevent severing throughthe bonding process, such as disclosed in U.S. Pat. No. 6,291,039.However, positioning hundreds of elastic strands drawn from a beam innesting grooves on an ultrasonic horn and/or anvil may add complexity tothe assembly process.

Consequently, it would be beneficial to provide methods and apparatusesfor producing elastomeric laminates by mechanically bonding elasticstrands between substrates without severing the elastics strands, and/orwithout the need for having to guide elastic strands into designatednesting grooves in a mechanical bonding device.

SUMMARY OF THE INVENTION

In one form, a method for making an elastomeric laminate comprises thesteps of: providing an elastic strand, wherein the elastic stranddefines a first cross sectional area in an unstretched state; stretchingthe elastic strand, wherein the stretched elastic strand defines asecond cross sectional area that is less than the first cross sectionalarea; advancing a first substrate and a second substrate with thestretched elastic strand between the first substrate and the secondsubstrate; applying heat and pressure to a first region of the firstsubstrate and a second region of the second substrate such thatmalleable first material of the first substrate and malleable secondmaterial of the second substrate deform to completely surround an outerperimeter of the stretched elastic strand, and removing heat andpressure from the first region of the first substrate and the secondregion of the second substrate to allow the malleable first material andthe malleable second material to harden to form a bond conforming with across sectional shape defined by the outer perimeter of the stretchedelastic strand; and applying a frictional lock between a portion of theelastic strand and the hardened first and second materials by releasingtension from the stretched elastic strand.

In another form, a method for making an elastomeric laminate comprisesthe steps of: providing an elastic strand, wherein the elastic stranddefines a first cross sectional area in an unstretched state; stretchingthe elastic strand, wherein the stretched elastic strand defines asecond cross sectional area that is less than the first cross sectionalarea; advancing a first substrate and a second substrate with thestretched elastic strands between the first substrate and the secondsubstrate; compressing first material of the first substrate and secondmaterial of the second substrate together in a bond region comprisingmalleable first material and malleable second material, wherein adiscrete length of the stretched elastic strand extends through the bondregion such that an outer perimeter of the discrete length of thestretched elastic strand is completely surrounded by the malleable firstmaterial and the malleable second material; allowing the malleable firstmaterial and the malleable second material to harden and conform with across sectional shape defined by the outer perimeter of the stretchedelastic strand; and applying a frictional lock between the discretelength of the elastic strand and the hardened first and second materialsby releasing tension from the stretched elastic strand.

In yet another form, a method for making an elastomeric laminatecomprises the steps of: positioning an elastic strand between a firstsubstrate and a second substrate, the elastic strand comprising an outerperimeter; heating a first region of the first substrate and a secondregion of the second substrate such that first material of the firstsubstrate and second material of the second substrate become malleable;and applying pressure to the first region, the second region, and theelastic strand together such that the malleable first material of thefirst substrate and the malleable second material of the secondsubstrate deform to completely surround the outer perimeter of theelastic strand, and removing pressure from the first region, the secondregion, and the elastic strand to allow the malleable first material andthe malleable second material to harden in a cross sectional shapeconforming with a cross sectional shape defined by the outer perimeterof the elastic strand; and applying a frictional lock between thediscrete length of the stretched elastic strand and the hardened firstand second materials by releasing tension from the stretched elasticstrand.

In still another form, a method for making an elastomeric laminatecomprises the steps of: providing an elastic strand, wherein the elasticstrand defines a first cross sectional area in an unstretched state;stretching the elastic strand, wherein the stretched elastic stranddefines a second cross sectional area that is less than the first crosssectional area; providing a substrate comprising a first surface and anopposing second surface; positioning the stretched elastic stand on thefirst surface of the substrate; folding a first portion of the substrateonto a second portion of the substrate with the stretched elastic strandpositioned between the first portion and the second portion of thesubstrate; applying heat and pressure to a first region of the firstportion and a second region of the second portion such that malleablematerial of the substrate deform to completely surround an outerperimeter of the stretched elastic strand, and removing heat andpressure from the first region and the second region to allow themalleable material to harden to define a cross sectional shapeconforming with a cross sectional shape defined by the outer perimeterof the stretched elastic strand; and applying a frictional lock betweena portion of the elastic strand and the hardened first and secondmaterials by releasing tension from the stretched elastic strand.

In still another form, an elastic laminate comprises: a first substratecomprising a first material; a second substrate comprising a secondmaterial; an elastic strand positioned between the first substrate andthe second substrate, the elastic strand comprising a length and anouter perimeter; discrete bond regions intermittently spaced along thelength of the elastic strand, the discrete bond regions comprising thefirst material and the second material completely surrounding andconforming with the outer perimeter of the elastic strand to define africtional lock.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a front perspective view of a diaper pant.

FIG. 1B is a rear perspective view of a diaper pant.

FIG. 2 is a partially cut away plan view of the diaper pant shown inFIGS. 1A and 1B in a flat, uncontracted state.

FIG. 3A is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3A-3A.

FIG. 3B is a cross-sectional view of the diaper pant of FIG. 2 takenalong line 3B-3B.

FIG. 4 shows an example of an empty beam having two side platesconnected with opposing end portions of a mandrel core.

FIG. 5 is a schematic side view of a converting apparatus joiningstretched elastic strands between a first substrate and a secondsubstrate.

FIG. 5A is a detailed view of an example bonding apparatus configuredwith an anvil and ultrasonic horn.

FIG. 6 is a view of the converting apparatus of FIG. 5 taken along line6-6.

FIG. 7A is a detailed view of an elastic strand in a stretched statebonded between the first and second substrates.

FIG. 7B shows a length of an elastic strand in a relaxed state with afirst cross sectional area.

FIG. 7C shows a length of the elastic strand of FIG. 7B in a stretchedstate with a second cross sectional area that is less than the firstcross sectional area.

FIG. 7D is a detailed view of an elastic strand in a relaxed statebonded between the first and second substrates.

FIG. 8A is a sectional view of the elastic strand, bond, firstsubstrate, and second substrate of FIG. 7A taken along line 8A-8A.

FIG. 8B is a sectional view of the elastic strand in a bonded region ofFIG. 7D taken along line 8B-8B, wherein the elastic strand is in arelaxed state.

FIG. 8C is a sectional view of the elastic strand in an unbonded regionof FIG. 7D taken along line 8C-8C, wherein the elastic strand is in arelaxed state.

FIG. 9A is a sectional view of an elastic strand, bond, first substrate,and second substrate of FIG. 7A taken along line 8A-8A, wherein aplurality of filaments of the elastic strand are bonded in a firstconfiguration.

FIG. 9B is a sectional view of an elastic strand, bond, first substrate,and second substrate of FIG. 7A taken along line 8A-8A, wherein aplurality of filaments of the elastic strand are bonded in a secondconfiguration.

FIG. 9C is a sectional view of an elastic strand, bond, first substrate,and second substrate of FIG. 7A taken along line 8A-8A, wherein aplurality of filaments of the elastic strand are bonded in a thirdconfiguration.

FIG. 9D is a scanning electron microscope (“SEM”) photograph of a crosssectional view of an elastic strand including five filaments in a bondedregion and surrounded by hardened first and second materials.

FIG. 9E is a scanning electron microscope (“SEM”) photograph of a crosssectional view of an elastic strand including five filaments in a bondedregion and surrounded by hardened first and second materials.

FIG. 9F is a scanning electron microscope (“SEM”) photograph of a crosssectional view of an elastic strand including fifteen filaments in abonded region and surrounded by hardened first and second materials.

FIG. 10 is a schematic side view of a second configuration of aconverting apparatus joining elastic strands between a first substrateand a second substrate, wherein the elastic strands drawn from differentbeams are stretched to have different elongations.

FIG. 11 is a view of the converting apparatus of FIG. 10 taken alongline 11-11.

FIG. 12 is a schematic side view of a third configuration of aconverting apparatus adapted to manufacture an elastomeric laminate.

FIG. 13 is a schematic side view of a fourth configuration of aconverting apparatus adapted to manufacture an elastomeric laminate.

FIG. 14 is a schematic side view of a fifth configuration of aconverting apparatus adapted to manufacture an elastomeric laminate.

FIG. 15 is a view of the converting apparatus of FIG. 14 taken alongline 15-15.

FIG. 16 is a view of the converting apparatus of FIG. 14 taken alongline 16-16.

FIG. 17 is a schematic side view of a sixth configuration of aconverting apparatus adapted to manufacture an elastomeric laminate.

DETAILED DESCRIPTION OF THE INVENTION

The following term explanations may be useful in understanding thepresent disclosure:

“Absorbent article” is used herein to refer to consumer products whoseprimary function is to absorb and retain soils and wastes. Absorbentarticles can comprise sanitary napkins, tampons, panty liners,interlabial devices, wound dressings, wipes, disposable diapersincluding taped diapers and diaper pants, inserts for diapers with areusable outer cover, adult incontinent diapers, adult incontinent pads,and adult incontinent pants. The term “disposable” is used herein todescribe absorbent articles which generally are not intended to belaundered or otherwise restored or reused as an absorbent article (e.g.,they are intended to be discarded after a single use and may also beconfigured to be recycled, composted or otherwise disposed of in anenvironmentally compatible manner).

An “elastic,” “elastomer” or “elastomeric” refers to materialsexhibiting elastic properties, which include any material that uponapplication of a force to its relaxed, initial length can stretch orelongate to an elongated length more than 10% greater than its initiallength and will substantially recover back to about its initial lengthupon release of the applied force.

As used herein, the term “joined” encompasses configurations whereby anelement is directly secured to another element by affixing the elementdirectly to the other element, and configurations whereby an element isindirectly secured to another element by affixing the element tointermediate member(s) which in turn are affixed to the other element.

The term “substrate” is used herein to describe a material which isprimarily two-dimensional (i.e. in an XY plane) and whose thickness (ina Z direction) is relatively small (i.e. 1/10 or less) in comparison toits length (in an X direction) and width (in a Y direction).Non-limiting examples of substrates include a web, layer or layers orfibrous materials, nonwovens, films and foils such as polymeric films ormetallic foils. These materials may be used alone or may comprise two ormore layers laminated together. As such, a web is a substrate.

The term “nonwoven” refers herein to a material made from continuous(long) filaments (fibers) and/or discontinuous (short) filaments(fibers) by processes such as spunbonding, meltblowing, carding, and thelike. Nonwovens do not have a woven or knitted filament pattern.

The term “machine direction” (MD) is used herein to refer to thedirection of material flow through a process. In addition, relativeplacement and movement of material can be described as flowing in themachine direction through a process from upstream in the process todownstream in the process.

The term “cross direction” (CD) is used herein to refer to a directionthat is generally perpendicular to the machine direction.

The term “taped diaper” (also referred to as “open diaper”) refers todisposable absorbent articles having an initial front waist region andan initial back waist region that are not fastened, pre-fastened, orconnected to each other as packaged, prior to being applied to thewearer. A taped diaper may be folded about the lateral centerline withthe interior of one waist region in surface to surface contact with theinterior of the opposing waist region without fastening or joining thewaist regions together. Example taped diapers are disclosed in varioussuitable configurations in U.S. Pat. Nos. 5,167,897, 5,360,420,5,599,335, 5,643,588, 5,674,216, 5,702,551, 5,968,025, 6,107,537,6,118,041, 6,153,209, 6,410,129, 6,426,444, 6,586,652, 6,627,787,6,617,016, 6,825,393, and 6,861,571; and U.S. Patent Publication Nos.2013/0072887 A1; 2013/0211356 A1; and 2013/0306226 A1, all of which areincorporated by reference herein.

The term “pant” (also referred to as “training pant”, “pre-closeddiaper”, “diaper pant”, “pant diaper”, and “pull-on diaper”) refersherein to disposable absorbent articles having a continuous perimeterwaist opening and continuous perimeter leg openings designed for infantor adult wearers. A pant can be configured with a continuous or closedwaist opening and at least one continuous, closed, leg opening prior tothe article being applied to the wearer. A pant can be preformed orpre-fastened by various techniques including, but not limited to,joining together portions of the article using any refastenable and/orpermanent closure member (e.g., seams, heat bonds, pressure welds,adhesives, cohesive bonds, mechanical fasteners, etc.). A pant can bepreformed anywhere along the circumference of the article in the waistregion (e.g., side fastened or seamed, front waist fastened or seamed,rear waist fastened or seamed). Example diaper pants in variousconfigurations are disclosed in U.S. Pat. Nos. 4,940,464; 5,092,861;5,246,433; 5,569,234; 5,897,545; 5,957,908; 6,120,487; 6,120,489;7,569,039 and U.S. Patent Publication Nos. 2003/0233082 A1; 2005/0107764A1, 2012/0061016 A1, 2012/0061015 A1; 2013/0255861 A1; 2013/0255862 A1;2013/0255863 A1; 2013/0255864 A1; and 2013/0255865 A1, all of which areincorporated by reference herein.

The present disclosure relates to methods for manufacturing absorbentarticles, and in particular, to methods for making elastomeric laminatesthat may be used as components of absorbent articles. The elastomericlaminates may include a first substrate, a second substrate, and anelastic material positioned between the first substrate and secondsubstrate. During the process of making the elastomeric laminate, theelastic material may be advanced and stretched in a machine directionand may be joined with either or both the first and second substratesadvancing in the machine direction. The methods and apparatusesaccording to the present disclosure may be configured with a pluralityof elastic strands wound onto a beam, and wherein one or more elasticstrands may comprise a spin finish. During assembly of an elastomericlaminate, the beam is rotated to unwind the elastic strands from thebeam. The elastic strands may also be stretched while advancing in amachine direction. Discrete mechanical bonds are applied to the firstsubstrate and the second substrate to secure elastic strandstherebetween, wherein the discrete bonds are arranged intermittentlyalong the machine direction. As discussed in more detail below, whencombining elastic strands having relatively low decitex values withsubstrates to create bonds having certain ranges of thicknesses, themechanical bonds can be applied to secure the elastic strands betweensubstrates without severing the elastics strands and without the needfor nesting grooves in a mechanical bonding device. It is to beappreciated that various types of mechanical bonding devices can beutilized with the apparatuses and methods herein, such as for example,heated or unheated patterned and anvil rolls and/or ultrasonic bondingdevices.

During the bonding process, heat and pressure are applied to the firstsubstrate and the second substrate such that malleable materials of thefirst and second substrates deform to completely surround an outerperimeter of a discrete length of the stretched elastic strand. Afterremoving the heat and pressure from the first and second substrates, themalleable materials harden to define a bond conforming with a crosssectional shape defined by the outer perimeter of the stretched elasticstrand. When the elastic strand is in a stretched state, the stretchedelastic strand defines a cross sectional area that is less than a crosssectional area of the elastic strand when in a relaxed state. Thus, whentension is released from the elastic strand, the cross sectional area ofthe elastic strand is prevented from expanding in the bond by thehardened materials of the first and second substrates, which in turn,creates forces between the elastic strand and the hardened materials.The forces between the elastic strand and the hardened materialsincreases the friction between the elastic strand and the hardenedmaterials. Thus, a frictional lock may be created between the elasticstrand and the hardened materials in the bond region by releasing thetension from the stretched elastic strands. The frictional lock holdsthe discrete length of the elastic strand in a fixed position in thebond region with the first and second substrates.

FIGS. 1A, 1B, and 2 show an example of an absorbent article 100 in theform of a diaper pant 100P that may include components constructed fromelastomeric laminates assembled in accordance with the apparatuses andmethods disclosed herein. In particular, FIGS. 1A and 1B showperspective views of a diaper pant 100P in a pre-fastened configuration,and FIG. 2 shows a plan view of the diaper pant 100P with the portion ofthe diaper that faces away from a wearer oriented toward the viewer. Thediaper pant 100P includes a chassis 102 and a ring-like elastic belt104. As discussed below in more detail, a first elastic belt 106 and asecond elastic belt 108 are bonded together to form the ring-likeelastic belt 104.

With continued reference to FIG. 2 , the diaper pant 100P and thechassis 102 each include a first waist region 116, a second waist region118, and a crotch region 119 disposed intermediate the first and secondwaist regions. The first waist region 116 may be configured as a frontwaist region, and the second waist region 118 may be configured as backwaist region. The diaper 100P may also include a laterally extendingfront waist edge 121 in the front waist region 116 and a longitudinallyopposing and laterally extending back waist edge 122 in the back waistregion 118. To provide a frame of reference for the present discussion,the diaper 100P and chassis 102 of FIG. 2 are shown with a longitudinalaxis 124 and a lateral axis 126. In some embodiments, the longitudinalaxis 124 may extend through the front waist edge 121 and through theback waist edge 122. And the lateral axis 126 may extend through a firstlongitudinal or right side edge 128 and through a midpoint of a secondlongitudinal or left side edge 130 of the chassis 102.

As shown in FIGS. 1A, 1B, and 2 , the diaper pant 100P may include aninner, body facing surface 132, and an outer, garment facing surface134. The chassis 102 may include a backsheet 136 and a topsheet 138. Thechassis 102 may also include an absorbent assembly 140, including anabsorbent core 142, disposed between a portion of the topsheet 138 andthe backsheet 136. As discussed in more detail below, the diaper 100Pmay also include other features, such as leg elastics and/or leg cuffsto enhance the fit around the legs of the wearer.

As shown in FIG. 2 , the periphery of the chassis 102 may be defined bythe first longitudinal side edge 128, a second longitudinal side edge130, a first laterally extending end edge 144 disposed in the firstwaist region 116, and a second laterally extending end edge 146 disposedin the second waist region 118. Both side edges 128 and 130 extendlongitudinally between the first end edge 144 and the second end edge146. As shown in FIG. 2 , the laterally extending end edges 144 and 146are located longitudinally inward from the laterally extending frontwaist edge 121 in the front waist region 116 and the laterally extendingback waist edge 122 in the back waist region 118. When the diaper pant100P is worn on the lower torso of a wearer, the front waist edge 121and the back waist edge 122 may encircle a portion of the waist of thewearer. At the same time, the side edges 128 and 130 may encircle atleast a portion of the legs of the wearer. And the crotch region 119 maybe generally positioned between the legs of the wearer with theabsorbent core 142 extending from the front waist region 116 through thecrotch region 119 to the back waist region 118.

As previously mentioned, the diaper pant 100P may include a backsheet136. The backsheet 136 may also define the outer surface 134 of thechassis 102. The backsheet 136 may also comprise a woven or nonwovenmaterial, polymeric films such as thermoplastic films of polyethylene orpolypropylene, and/or a multi-layer or composite materials comprising afilm and a nonwoven material. The backsheet may also comprise anelastomeric film. An example backsheet 136 may be a polyethylene filmhaving a thickness of from about 0.012 mm (0.5 mils) to about 0.051 mm(2.0 mils). Further, the backsheet 136 may permit vapors to escape fromthe absorbent core (i.e., the backsheet is breathable) while stillpreventing exudates from passing through the backsheet 136.

Also described above, the diaper pant 100P may include a topsheet 138.The topsheet 138 may also define all or part of the inner surface 132 ofthe chassis 102. The topsheet 138 may be liquid pervious, permittingliquids (e.g., menses, urine, and/or runny feces) to penetrate throughits thickness. A topsheet 138 may be manufactured from a wide range ofmaterials such as woven and nonwoven materials; apertured or hydroformedthermoplastic films; apertured nonwovens, porous foams; reticulatedfoams; reticulated thermoplastic films; and thermoplastic scrims. Wovenand nonwoven materials may comprise natural fibers such as wood orcotton fibers; synthetic fibers such as polyester, polypropylene, orpolyethylene fibers; or combinations thereof. If the topsheet 138includes fibers, the fibers may be spunbond, carded, wet-laid,meltblown, hydroentangled, or otherwise processed as is known in theart. Topsheets 138 may be selected from high loft nonwoven topsheets,apertured film topsheets and apertured nonwoven topsheets. Exemplaryapertured films may include those described in U.S. Pat. Nos. 5,628,097;5,916,661; 6,545,197; and 6,107,539.

As mentioned above, the diaper pant 100P may also include an absorbentassembly 140 that is joined to the chassis 102. As shown in FIG. 2 , theabsorbent assembly 140 may have a laterally extending front edge 148 inthe front waist region 116 and may have a longitudinally opposing andlaterally extending back edge 150 in the back waist region 118. Theabsorbent assembly may have a longitudinally extending right side edge152 and may have a laterally opposing and longitudinally extending leftside edge 154, both absorbent assembly side edges 152 and 154 may extendlongitudinally between the front edge 148 and the back edge 150. Theabsorbent assembly 140 may additionally include one or more absorbentcores 142 or absorbent core layers. The absorbent core 142 may be atleast partially disposed between the topsheet 138 and the backsheet 136and may be formed in various sizes and shapes that are compatible withthe diaper. Exemplary absorbent structures for use as the absorbent coreof the present disclosure are described in U.S. Pat. Nos. 4,610,678;4,673,402; 4,888,231; and 4,834,735.

Some absorbent core embodiments may comprise fluid storage cores thatcontain reduced amounts of cellulosic airfelt material. For instance,such cores may comprise less than about 40%, 30%, 20%, 10%, 5%, or even1% of cellulosic airfelt material. Such a core may comprise primarilyabsorbent gelling material in amounts of at least about 60%, 70%, 80%,85%, 90%, 95%, or even about 100%, where the remainder of the corecomprises a microfiber glue (if applicable). Such cores, microfiberglues, and absorbent gelling materials are described in U.S. Pat. Nos.5,599,335; 5,562,646; 5,669,894; and 6,790,798 as well as U.S. PatentPublication Nos. 2004/0158212 A1 and 2004/0097895 A1.

As previously mentioned, the diaper 100P may also include elasticizedleg cuffs 156. It is to be appreciated that the leg cuffs 156 can be andare sometimes also referred to as leg bands, side flaps, barrier cuffs,elastic cuffs or gasketing cuffs. The elasticized leg cuffs 156 may beconfigured in various ways to help reduce the leakage of body exudatesin the leg regions. Example leg cuffs 156 may include those described inU.S. Pat. Nos. 3,860,003; 4,909,803; 4,695,278; 4,795,454; 4,704,115;4,909,803; and U.S. Patent Publication No. 2009/0312730 A1.

As mentioned above, diaper pants may be manufactured with a ring-likeelastic belt 104 and provided to consumers in a configuration whereinthe front waist region 116 and the back waist region 118 are connectedto each other as packaged, prior to being applied to the wearer. Assuch, diaper pants may have a continuous perimeter waist opening 110 andcontinuous perimeter leg openings 112 such as shown in FIGS. 1A and 1B.The ring-like elastic belt may be formed by joining a first elastic beltto a second elastic belt with a permanent side seam or with an openableand reclosable fastening system disposed at or adjacent the laterallyopposing sides of the belts.

As previously mentioned, the ring-like elastic belt 104 may be definedby a first elastic belt 106 connected with a second elastic belt 108. Asshown in FIG. 2 , the first elastic belt 106 extends between a firstlongitudinal side edge 111 a and a second longitudinal side edge 111 band defines first and second opposing end regions 106 a, 106 b and acentral region 106 c. And the second elastic 108 belt extends between afirst longitudinal side edge 113 a and a second longitudinal side edge113 b and defines first and second opposing end regions 108 a, 108 b anda central region 108 c. The distance between the first longitudinal sideedge 111 a and the second longitudinal side edge 111 b defines the pitchlength, PL, of the first elastic belt 106, and the distance between thefirst longitudinal side edge 113 a and the second longitudinal side edge113 b defines the pitch length, PL, of the second elastic belt 108. Thecentral region 106 c of the first elastic belt is connected with thefirst waist region 116 of the chassis 102, and the central region 108 cof the second elastic belt 108 is connected with the second waist region118 of the chassis 102. As shown in FIGS. 1A and 1B, the first endregion 106 a of the first elastic belt 106 is connected with the firstend region 108 a of the second elastic belt 108 at first side seam 178,and the second end region 106 b of the first elastic belt 106 isconnected with the second end region 108 b of the second elastic belt108 at second side seam 180 to define the ring-like elastic belt 104 aswell as the waist opening 110 and leg openings 112.

As shown in FIGS. 2, 3A, and 3B, the first elastic belt 106 also definesan outer laterally extending edge 107 a and an inner laterally extendingedge 107 b, and the second elastic belt 108 defines an outer laterallyextending edge 109 a and an inner laterally extending edge 109 b. Assuch, a perimeter edge 112 a of one leg opening may be defined byportions of the inner laterally extending edge 107 b of the firstelastic belt 106, the inner laterally extending edge 109 b of the secondelastic belt 108, and the first longitudinal or right side edge 128 ofthe chassis 102. And a perimeter edge 112 b of the other leg opening maybe defined by portions of the inner laterally extending edge 107 b, theinner laterally extending edge 109 b, and the second longitudinal orleft side edge 130 of the chassis 102. The outer laterally extendingedges 107 a, 109 a may also define the front waist edge 121 and thelaterally extending back waist edge 122 of the diaper pant 100P. Thefirst elastic belt and the second elastic belt may also each include anouter, garment facing layer 162 and an inner, wearer facing layer 164.It is to be appreciated that the first elastic belt 106 and the secondelastic belt 108 may comprise the same materials and/or may have thesame structure. In some embodiments, the first elastic belt 106 and thesecond elastic belt may comprise different materials and/or may havedifferent structures. It should also be appreciated that the firstelastic belt 106 and the second elastic belt 108 may be constructed fromvarious materials. For example, the first and second belts may bemanufactured from materials such as plastic films; apertured plasticfilms; woven or nonwoven webs of natural materials (e.g., wood or cottonfibers), synthetic fibers (e.g., polyolefins, polyamides, polyester,polyethylene, or polypropylene fibers) or a combination of naturaland/or synthetic fibers; or coated woven or nonwoven webs. In someembodiments, the first and second elastic belts include a nonwoven webof synthetic fibers, and may include a stretchable nonwoven. In otherembodiments, the first and second elastic belts include an innerhydrophobic, non-stretchable nonwoven material and an outer hydrophobic,non-stretchable nonwoven material.

The first and second elastic belts 106, 108 may also each include beltelastic material interposed between the outer substrate layer 162 andthe inner substrate layer 164. The belt elastic material may include oneor more elastic elements such as strands, ribbons, films, or panelsextending along the lengths of the elastic belts. As shown in FIGS. 2,3A, and 3B, the belt elastic material may include a plurality of elasticstrands 168 which may be referred to herein as outer, waist elastics 170and inner, waist elastics 172. Elastic strands 168, such as the outerwaist elastics 170, may continuously extend laterally between the firstand second opposing end regions 106 a, 106 b of the first elastic belt106 and between the first and second opposing end regions 108 a, 108 bof the second elastic belt 108. In some embodiments, some elasticstrands 168, such as the inner waist elastics 172, may be configuredwith discontinuities in areas, such as for example, where the first andsecond elastic belts 106, 108 overlap the absorbent assembly 140. Insome embodiments, the elastic strands 168 may be disposed at a constantinterval in the longitudinal direction. In other embodiments, theelastic strands 168 may be disposed at different intervals in thelongitudinal direction. The belt elastic material in a stretchedcondition may be interposed and joined between the uncontracted outerlayer and the uncontracted inner layer. When the belt elastic materialis relaxed, the belt elastic material returns to an unstretchedcondition and contracts the outer layer and the inner layer. The beltelastic material may provide a desired variation of contraction force inthe area of the ring-like elastic belt. It is to be appreciated that thechassis 102 and elastic belts 106, 108 may be configured in differentways other than as depicted in FIG. 2 . The belt elastic material may bejoined to the outer and/or inner layers continuously or intermittentlyalong the interface between the belt elastic material and the innerand/or outer belt layers.

In some configurations, the first elastic belt 106 and/or second elasticbelt 108 may define curved contours. For example, the inner lateraledges 107 b, 109 b of the first and/or second elastic belts 106, 108 mayinclude non-linear or curved portions in the first and second opposingend regions. Such curved contours may help define desired shapes to legopening 112, such as for example, relatively rounded leg openings. Inaddition to having curved contours, the elastic belts 106, 108 mayinclude elastic strands 168, 172 that extend along non-linear or curvedpaths that may correspond with the curved contours of the inner lateraledges 107 b, 109 b.

As previously mentioned, apparatuses and methods according to thepresent disclosure may be utilized to produce elastomeric laminates thatmay be used to construct various components of diapers, such as elasticbelts, leg cuffs, and the like. For example, FIGS. 4-17 show variousaspects of converting apparatuses 300 adapted to manufacture elastomericlaminates 302. As described in more detail below, the convertingapparatuses 300 operate to advance a continuous length of elasticmaterial 304, a continuous length of a first substrate 306, and acontinuous length of a second substrate 308 along a machine directionMD. The apparatus 300 stretches the elastic material 304 and joins thestretched elastic material 304 with the first and second substrates 306,308 to produce an elastomeric laminate 302. Although the elasticmaterial 304 is illustrated and referred to herein as strands, it is tobe appreciated that elastic material 304 may include one or morecontinuous lengths of elastic strands, ribbons, and/or films.

It is to be appreciated that the elastomeric laminates 302 may be usedto construct various types of absorbent article components. For example,the elastomeric laminates 302 may be used as a continuous length ofelastomeric belt material that may be converted into the first andsecond elastic belts 106, 108 discussed above with reference to FIGS.1-3B. As such, the elastic material 304 may correspond with the beltelastic material 168 interposed between the outer layer 162 and theinner layer 164, which in turn, may correspond with either the firstand/or second substrates 306, 308. In other examples, the elastomericlaminates may be used to construct waistbands and/or side panels intaped diaper configurations. In yet other examples, the elastomericlaminates may be used to construct various types of leg cuff and/ortopsheet configurations.

As discussed in more detail below, the converting apparatuses 300 mayinclude metering devices arranged along a process machine direction MD,wherein the metering devices may be configured to stretch the advancingelastic material and/or join stretch elastic material with one or moreadvancing substrates. In some configurations, a metering device maycomprise a beam of elastic strands wound thereon. During operation,elastic material may advance in a machine direction from a rotating beamto a downstream metering device to be joined with one or more advancingsubstrates. The elastic material advancing from the rotating beam mayinclude a spin finish, and as such, the apparatuses herein may beconfigured to bond the elastic material with the substrates withouthaving to remove the spin finish before joining the elastic materialwith the substrates. Bonds are applied to the first substrate and thesecond substrate to secure discrete lengths of the stretched elasticstrands between the first and second substrates. The discrete bonds maybe arranged intermittently along the machine direction. In someconfigurations, the bonds extend in the machine direction and may extendin a cross direction across one or more elastic strands. In someconfigurations, bonds may be separated from each other in a crossdirection. It is to be appreciated that the apparatuses and methods ofassembly of elastomeric laminates and absorbent articles describedherein and illustrated in the accompanying drawings are non-limitingexample configurations. The features illustrated or described inconnection with one non-limiting configuration may be combined with thefeatures of other non-limiting configurations. Such modifications andvariations are intended to be included within the scope of the presentdisclosure.

As shown in FIGS. 5 and 6 , a converting apparatus 300 for producing anelastomeric laminate 302 may include a first metering device 310 and asecond metering device 312. The first metering device 310 may beconfigured as a beam 314 with a plurality of elastic strands 316 woundthereon. FIG. 4 shows an example of an empty beam 314 that includes twoside plates 317 a, 317 b that may be connected with opposing endportions of a mandrel core 318, wherein elastic strands may be woundonto the mandrel core 318. It is to be appreciated that beams of varioussizes and technical specifications may be utilized in accordance withthe methods and apparatuses herein, such as for example, beams that areavailable from ALUCOLOR Textilmaschinen, GmbH. During operation, theplurality of elastic strands 316 advance in the machine direction MDfrom the beam 314 to the second metering device 312. In addition, theplurality of elastic strands 316 may be stretched along the machinedirection MD between the beam 314 and the second metering device 312.The stretched elastic strands 316 are also joined with a first substrate306 and a second substrate 308 at the second metering device 312 toproduce an elastomeric laminate 302. In some configurations, one or moreof the elastic strands 316 advancing from the beam 314 may also includea spin finish 320 located on outer surfaces of the elastics strands. Inturn, stretched elastic strands 316 may be connected between the firstsubstrate 306 and the second substrate 308 with bonds 322. The bonds 322may be configured as discrete mechanical bonds 322 applied to the firstsubstrate 306 and the second substrate 308 to secure the elastic strands316. The discrete bonds 322 may be arranged intermittently along themachine direction. In some configurations, the bonds 322 extend in themachine direction MD and may extend in the cross direction CD across oneor more elastic strands 316. In some configurations, discrete bonds 322may also be separated from each other in the cross direction CD.

It is to be appreciated the elastic strands 316 may include varioustypes of spin finish 320, also referred herein as yarn finish,configured as coating on the elastic strands 316 that may be intended tohelp prevent the elastics strands from adhering to themselves, eachother, and/or downstream handling equipment. In some configurations, aspin finish may include various types of oils and other components, suchas disclosed for example in U.S. Pat. Nos. 8,377,554; 8,093,161; and6,821,301. In some configurations, a spin finish may include varioustypes of silicone oils, such as for example, polydimethylsiloxane. Insome configurations, a spin finish may include various types of mineraloils. It is to be appreciated that the amount of spin finish applied toelastic strands may be optimized depending on the process configurationin which the elastic strands may be used. For example, in processconfigurations wherein elastic strands have limited contact or do notcontact downstream handling equipment, such as idlers, the amount ofspin finish may be selected to help prevent the elastics strands fromadhering to themselves and/or each other while wound on a beam withoutregard to whether elastic strands would adhere to downstream handlingequipment. As such, it is to be appreciated that the elastic strandsherein may include various amounts of spin finish that may be expressedin various ways. For example, a quantity of 10 grams of spin finish per1 kilogram of elastic strand may be expressed as 1% spin finish. In someconfigurations, an elastic strand may include about 0.1% spin finish. Insome configurations, a strand may include from about 0.01% to about 10%spin finish, specifically reciting all 0.01% increments within theabove-recited range and all ranges formed therein or thereby.

As shown in FIGS. 5 and 6 , the second metering device 312 may include:a first roller 324 having an outer circumferential surface 326 and thatrotates about a first axis of rotation 328, and a second roller 330having an outer circumferential surface 332 and that rotates about asecond axis of rotation 334. The first roller 324 and the second roller330 rotate in opposite directions, and the first roller 324 is adjacentthe second roller 330 to define a nip 336 between the first roller 324and the second roller 330. The first roller 324 rotates such that theouter circumferential surface 326 has a surface speed S1, and the secondroller 330 may rotate such that the outer circumferential surface 332has the same, or substantially the same, surface speed S1.

With continued reference to FIGS. 5 and 6 , the first substrate 306includes a first surface 338 and an opposing second surface 340, and thefirst substrate 306 advances to the first roller 324. In particular, thefirst substrate 306 advances at speed S1 to the first roller 324 wherethe first substrate 306 partially wraps around the outer circumferentialsurface 326 of the first roller 324 and advances through the nip 336. Assuch, the first surface 338 of the first substrate 306 travels in thesame direction as and in contact with the outer circumferential surface326 of the first roller 324. In addition, the second substrate 308includes a first surface 342 and an opposing second surface 344, and thesecond substrate 308 advances to the second roller 330. In particular,the second substrate 308 advances at speed S1 to the second roller 330where the second substrate 308 partially wraps around the outercircumferential surface 332 of the second roller 330 and advancesthrough the nip 336. As such, the second surface 344 of the secondsubstrate 308 travels in the same direction as and in contact with theouter circumferential surface 332 of the second roller 330.

Still referring to FIGS. 5 and 6 , the beam 314 includes elastic strands316 wound thereon, and the beam 314 is rotatable about a beam rotationaxis 346. In some configurations, the beam rotation axis 346 may extendin the cross direction CD. As the beam 314 rotates, the elastic strands316 advance from the beam 314 at a speed S2 with the elastic strands 316being spaced apart from each other in the cross direction CD. From thebeam 314, the elastic strands 316 advance in the machine direction MD tothe nip 336. In some configurations, the speed S2 is less than the speedS1, and as such, the elastic strands 316 are stretched in the machinedirection MD. In turn, the stretched elastic strands 316 advance throughthe nip 336 between the first and second substrates 306, 308 such thatthe elastic strands 316 are joined with the second surface 340 of thefirst substrate 306 and the first surface 342 of the second substrate308 to produce a continuous length of elastomeric laminate 302.

It is to be appreciated that the beam 314 may be configured in variousways and with various quantities of elastic strands. Example beams, alsoreferred to as warp beams, that may be used with the apparatus andmethods herein are disclosed in U.S. Pat. Nos. 4,525,905; 5,060,881; and5,775,380; and U.S. Patent Publication No. 2004/0219854 A1. AlthoughFIG. 6 shows five elastic strands 316 advancing from the beam 314, it isto be appreciated that the apparatuses herein may be configured suchthat more or less than five elastic strands 316 advance from the beam314. In some configurations, the elastic strands 316 advancing from thebeam 314 may include from about 100 to about 2000 strands, specificallyreciting all 1 strand increments within the above-recited range and allranges formed therein or thereby. In some configurations, the elasticstrands 316 may be separated from each other by about 0.5 mm to about 4mm in the cross direction, specifically reciting all 0.1 mm incrementswithin the above-recited range and all ranges formed therein or thereby.As discussed herein, the elastics in the plurality of elastic strandsmay be pre-strained prior to joining the elastic strand to the first orsecond substrate layers 306, 308. In some configurations, the elasticmay be pre-strained from about 75% to about 300%, specifically recitingall 1% increments within the above-recited range and all ranges formedtherein or thereby. It is also to be appreciated that one or more beamsof elastics may be arranged along the cross direction CD of a convertingprocess and/or arranged along a machine direction MD in variousdifferent portions of a converting process. It is also to be appreciatedthat the beam 314 can be connected with one or more motors, such asservo motors, to drive and control the rotation of the beam 314. It isto be appreciated that in some configurations, the elastic strands 316may be supplied on the beam 314 in a stretched state, and as such, maynot require additional stretching (or may require relatively lessadditional stretching) before being combined with the first substrate306 and/or the second substrate 308. In some configurations, an elasticstrand 316 may be drawn from a single roll utilizing a rolling unwind,such as for example, available from Overend Technologies, Inc.

With continued reference to FIGS. 5 and 6 , the advancing elasticstrands 316 may be joined with the first substrate 306 and the secondsubstrate 308 to form the elastomeric laminate 302. The elastic laminate302 may also advance past a bond applicator 348 configured to applybonds 322 that secure the elastic strands 316 between the firstsubstrate 306 and the second substrate 308. One or more of the elasticstrands 316 advancing from the beam 314 may include a spin finish 320.As such, the bonds 322 may be configured to secure the elastic strands316 between the first and second substrates 306, 308 without having toremove the spin finish 320 from the elastic strands 316. It is also tobe appreciated that the methods and apparatuses herein may also beconfigured to remove the spin finish 320 from the elastic strands 316.Examples of spin finish removal processes and apparatuses are disclosedin U.S. Provisional Patent Application No. 62/483,965, which isincorporated by reference herein. In addition, the elastic laminates 302herein may be constructed with or without adhesives between the firstand second substrates 306, 308. In addition, it is to be appreciatedthat the bonding methods and apparatuses herein may be utilized inconjunction with other bonding methods and apparatuses, such asdisclosed in U.S. Patent Application No. 62/553,149, filed on Sep. 1,2017, which is incorporated by reference herein.

As shown in FIG. 6 , the bonds 322 may extend for discrete lengths alongthe machine direction MD and may be intermittently arranged along themachine direction of the elastic laminate 302. Thus, the elastic strands316 may extend in the machine direction MD between intermittently spacedbond regions 360 and unbonded regions 362. It is to be appreciated thatthe bonds 322 may extend contiguously for various lengths in the crossdirection CD and may extend across one or more elastic strands 316. Thebonds 322 may also be separated from each other in the cross directionCD, such as shown for example in FIG. 11 .

FIGS. 7A and 8A are detailed views of an elastic strand 316 in astretched state secured with bonds 322 between the first and secondsubstrates 306, 308. During the bonding process, the bond applicator 348may apply heat and pressure to a first region 350 of the first substrate306 and a second region 352 of the second substrate 308 such that firstmaterial 354 of the first substrate 306 and second material 356 of thesecond substrate 308 become malleable. In turn, the malleable first andsecond materials 354, 356 deform and completely surround an outerperimeter 358 of a discrete length of the stretched elastic strand 316in a bond region 360. The heat and pressure are removed from the firstregion 350 of the first substrate 306 and the second region 352 of thesecond substrate 308 as the elastic laminate 302 advances from the bondapplicator 348, and as such, the malleable first and second materials354, 356 harden in a bond 322 that conforms with a cross sectional shapedefined by the outer perimeter 358 of the stretched elastic strand 316.In some configurations, an external heat source may be used to generatethe heat used in the bonding process, such as with a heated anvil. It isalso to be appreciated that heat may be generated solely by the bondingprocess, such as for example, heat generated by an ultrasonic hornvibration or heat generated by a fusion bonding process, wherein noexternal heat source is required. In some configurations, tooling usedin the bonding process may also be chilled to help provide and/orcontrol the process temperatures at desired levels.

It is to be appreciated that the bond applicator 348 may be configuredin various ways, such as for example, heated or unheated patterned andanvil rolls and/or ultrasonic bonding devices. When configured as anultrasonic bonding device such as schematically shown in FIGS. 5 and 5A,the bond applicator 348 may include a horn 349 a and may be configuredto impart ultrasonic energy to the combined substrates 306, 308 andelastic strands 316 on an anvil 349 b. In turn, the anvil 349 b mayinclude a plurality of pattern elements 349 c protruding radiallyoutward from the anvil 349 b, wherein each pattern element includes apattern surface 349 d. It is to be appreciated that the number, size,and shape of some or all the pattern surfaces and/or pattern elementsmay be different. In some embodiments, the shape and size of the patternsurface 349 d of each pattern element 349 c may be identical orsubstantially identical to each other. In some configurations, thepattern elements 349 c and/or pattern surfaces 349 d may have aperimeter that defines circular, square, rectangular, elliptical, andvarious types of other shapes. In some configurations, the anvil 349 bmay include a pattern element 349 c with a pattern surface 349 d thatdefines a continuous crossing line pattern and/or various other shapes,such as disclosed in U.S. Pat. No. 9,265,672, which is incorporated byreference herein. It is to be appreciated that the pattern surface 349d, such as discussed above, may be flat and/or may also include regionsdefined by relatively high and relatively low elevations. Thus, suchpattern surfaces may create bonds 322 having varying thicknesses acrossthe bond region 360. In addition, it is to be appreciated that anelastic strand 316 may extend across such relatively high and lowelevations during the bonding process. It is to be appreciated that thechoice of pattern surface shape may enable the creation of uniquetextures and patterns where the location and size of the bonding sitesimpact local buckling resistance of a nonwoven laminate and may createdesired homogeneous textures upon relaxation of the elastics and theresulting nonwoven corrugation.

With continued reference to FIGS. 5 and 5A, the ultrasonic bondingdevice may apply energy to the horn 349 a to create resonance of thehorn at frequencies and amplitudes so the horn vibrates rapidly in adirection generally perpendicular to the substrates 306, 308 and elasticstrands 316 being advanced past the horn 349 a on the anvil 349 b.Vibration of the horn 349 a generates heat to melt and bond thesubstrates 306, 308 together in areas supported by the pattern elements349 c on the anvil 349 b. Thus, the bonds 322 and/or bond regions 360may have shapes that correspond with and may mirror shapes of thepattern surfaces 349 d. As shown in FIG. 5A, the pattern surface 349 dmay extend contiguously across one or more elastic strands 316positioned between the first substrate 306, and the second substrate308. It is to be appreciated that aspects of the ultrasonic bondingdevices may be configured in various ways, such as for example linear orrotary type configurations, and such as disclosed for example in U.S.Pat. Nos. 3,113,225; 3,562,041; 3,733,238; 5,110,403; 6,036,796;6,508,641; and 6,645,330. In some configurations, the ultrasonic bondingdevice may be configured as a linear oscillating type sonotrode, such asfor example, available from Herrmann Ultrasonic, Inc. In someconfigurations, the sonotrode may include a plurality of sonotrodesnested together in the cross direction CD. The bond applicator 348 mayalso be configured in various other ways, such as for example, themechanical bonding devices and methods disclosed in U.S. Pat. Nos.4,854,984; 6,248,195; 8,778,127; and 9,005,392; and U.S. PatentPublication Nos. 2014/0377513 A1; and 2014/0377506 A1. Although the bondapplicator 348 is shown in FIGS. 5 and 6 as a separate device that ispositioned downstream of the second metering device 312, it is to beappreciated the second metering device 312 may also be configured as thebond applicator 348. As such, the first substrate 306, second substrate308, and elastic strands 316 may be combined and bonded together at thebond applicator 348 to form the elastic laminate 302.

As previously mentioned, a frictional lock may be applied between aportion of the elastic strand 316 and the hardened first and secondmaterials 354, 356 by releasing tension from the stretched elasticstrand 316. The frictional lock acts to hold and/or secure the elasticstrand 316 in a fixed position in the bond region 360. For the purposesof a general explanation, FIG. 7B shows a length of an elastic strand316 in a unstretched or relaxed state, wherein the elastic strand 316defines a first cross sectional area A1. And FIG. 7C shows a length ofthe elastic strand 316 from FIG. 7B in a stretched state, wherein theelastic strand 316 defines a second cross sectional area A2 that is lessthan the first cross sectional area A1. Thus, the cross sectional areaof the stretched elastic strand 316 expands when tension is partially orfully released from the elastic strand 316. As discussed in more detailbelow, the tendency of the cross sectional area of the elastic strand316 to expand helps create the frictional lock.

Turning next to FIG. 7D, a detailed view of an elastic strand 316, suchas shown in FIG. 7A, is provided wherein tension has been released (orreduced) on the elastic strand 316 and showing how the tendency of theelastic strand 316 to expand creates a frictional lock in the bondedregion 360. FIGS. 7D and 8B show the elastic strand 316 as having afirst cross sectional area A1 in an unbonded region 362 of the elasticlaminate 302, wherein the first cross sectional area A1 is greater thanthe second cross sectional area A2 of the stretched elastic strand 316shown in FIGS. 7A and 8A. And FIGS. 7D and 8C show the elastic strand316 as having a third cross sectional area A3 in the bond region 360 ofthe elastic laminate 302, wherein the third cross sectional area A3 isthe same or about the same as the second cross sectional area A2 of thestretched elastic strand 316 shown in FIGS. 7A and 8A. As shown in FIG.8C, the hardened first and second materials 354, 356 in the bond region360 help prevent the cross sectional area of the elastic strand 316 fromexpanding when tension has on elastic strand 316 has been reduced. Thetendency of the elastic strand 316 to expand creates forces F(represented by dashed double arrow lines in FIG. 8C) exerted betweenthe hardened first and second materials 354, 356 in the bond region 360.In turn, the forces F between the elastic strand 316 and the hardenedfirst and second materials 354, 356 creates a frictional lock byincreasing the friction forces between the elastic strand 316 and thehardened materials 354, 356. The increased friction forces in themachine direction MD along the length of the elastic strand 316 in thebond region 360 holds the discrete length of the elastic strand 316 in afixed position in the bond region 360 together with the first and secondsubstrates 306, 308. As such, in some configurations, no adhesive may beapplied to and/or present between the elastic strand 316 and thehardened materials 354, 356. It is also to be appreciated that in someconfigurations, adhesive may be applied to and/or present between theelastic strand 316 and the hardened materials 354, 356 to help thefrictional lock hold the discrete length of the elastic strand 316 in afixed position in the bond region 360 together with the first and secondsubstrates 306, 308. In some configurations, adhesive and the frictionallock in the bond regions 360 may share the load exerted by elasticstrand 316. In some configurations, adhesive positioned on the elasticstrand 316 may increase the coefficient of friction between the elasticstrand 316 and the hardened materials 354, 356 in the bond region 360.It is to be appreciated that various quantities of adhesive may bepresent in the bond regions 360, such as for example, about 10 gsm orless.

It is also to be appreciated that the elastic strands 316 herein bondedin accordance with the methods described herein may also be constructedfrom one or more filaments 364. For example, FIG. 9A shows a crosssectional view of an elastic strand 316 in a bond region 360 wherein theelastic strand 316 comprises a plurality of individual filaments 364. Asshown in FIG. 9A, the elastics strand 316 includes outer filaments 364 asurrounding an inner filament 364 b. The outer filaments 364 a definethe outer perimeter 358 of the elastic strand 316, and the outerfilaments 364 a may surround the inner filament 364 b such that theinner filament 364 b is not in contact with the hardened first material354 and the hardened second material 356 in the bond 322. It is to beappreciated that the filaments 364 may be arranged in various positionswithin the bond region 360. For example, FIG. 9B shows a cross sectionalview of an elastic strand 316 in a bond region 360 wherein the pluralityof individual filaments 364 together define a perimeter 358 that iselongated along the cross direction CD, and wherein all of the pluralityof filaments 364 are in contact with hardened first material 354 andhardened second material 356. In another example, FIG. 9C shows a crosssectional view of an elastic strand 316 in a bond region 360 wherein atleast two of the filaments 364 are separated from each other by at leastone of hardened first material 354 and hardened second material 356.

It is to be appreciated that different components may be used toconstruct the elastomeric laminates 302 in accordance with the methodsand apparatuses herein. For example, the first and/or second substrates306, 308 may include nonwovens and/or films and may be constructed fromvarious types of materials, such as plastic films; apertured plasticfilms; woven or nonwoven webs of natural materials, such as wood orcotton fibers; synthetic fibers, such as polyolefins, polyamides,polyester, polyethylene, or polypropylene fibers or a combination ofnatural and/or synthetic fibers; or coated woven or nonwoven webs;polymeric films such as thermoplastic films of polyethylene orpolypropylene, and/or a multi-layer or composite materials comprising afilm and a nonwoven material.

It is also to be appreciated that the strands 316 and/or filaments 364herein may define various different cross-sectional shapes. For example,in some configurations, strands 316 or filaments 364 may definecircular, oval, or elliptical cross sectional shapes or irregularshapes, such as dog bone and hourglass shapes. In addition, the elasticstrands 316 may be configured in various ways and with various decitexvalues. In some configurations, the elastic strands 316 may beconfigured with decitex values ranging from about 10 decitex to about500 decitex, specifically reciting all 1 decitex increments within theabove-recited range and all ranges formed therein or thereby.

As previously mentioned, substrates 306, 308 with elastic strands 316positioned therebetween can be bonded in accordance with methods hereinwithout severing the elastics strands and without the need for nestinggrooves in bond applicator 348. For example, as shown in FIGS. 8C and9A-9C, heat and pressure may be applied to the substrates 306, 308 tocreate bonds 322 surrounding the elastic strand 316. The bond 322 isdefined by hardened first material 354 and hardened second material 356and has a minimum thickness Tb. In addition, the elastic strand 316 mayhave a thickness Te in the bond region 360. In some configurations,substrates 306, 308 that are bonded together to create a bond thicknessTb having a certain size relative to the elastic strand thickness Te,the elastic strand 316 may not be severed during the bonding process. Inaddition, the forces F exerted between the elastic strand 316 and thehardened first and second materials 354, 356 in the bond region 360 maybe prevented from breaking the bond 322. Such a relationship between Teand Tb may be characterized by the decitex of elastic strands 316 andthe bond thickness Tb. For example, substrates 306, 308 may be bondedtogether with an elastic strand having a decitex value less than orequal to about 70 positioned therebetween to create a bond 322 having athickness Tb of at least about 100 μm (“microns”) without severing theelastic strand 316. In another example, substrates 306, 308 may bebonded together with an elastic strand having a decitex value less thanor equal to about 250 positioned therebetween to create a bond 322having a thickness Tb of at least about 200 μm (“microns”) withoutsevering the elastic strand 316. In some configurations, such as shownin FIG. 9C, the bond thickness Tb may be at least 50% larger than theminimum cross sectional thickness Tf a filament 364. For example, asshown in FIG. 9C, the minimum cross sectional thickness Tf of a filament364 having a circular cross section may be defined the diameter of sucha filament.

FIGS. 9D-9F electron microscope photographs (“SEM”) showing crosssectional views of an elastic strand 316 in a bond region 360 surroundedby hardened first and second materials 354, 356 from two nonwovens. InFIGS. 9D and 9E, the elastic strand 316 is a 70 decitex elastic strandincluding five filaments 364, wherein each filament 364 has a diameterof about 43 μm (“microns”). And the bond 322 defines a thickness Tb ofabout 80 μm (“microns”). In FIG. 9F, the elastic strand 316 is a 235decitex elastic strand including fifteen filaments 364, wherein eachfilament 364 has a diameter of about 43 μm (“microns”). And the bond 322defines a thickness Tb of about 200 μm (“microns”).

It is to be appreciated that the apparatuses 300 herein may beconfigured in various ways with various features described herein toassemble elastomeric laminates 302 having various stretchcharacteristics. For example, the apparatus 300 may be configured toassemble elastomeric laminates 302 with elastic strands 316 unwound frommore than one beam and/or in combination with elastic stands suppliedfrom an overend or surface driven unwinder. For example, FIGS. 10 and 11illustrate the apparatus 300 configured to assemble elastomericlaminates 302 with elastic strands 316 unwound from more than one beam314. In particular, the apparatus 300 may include a first beam 314 awith first elastic strands 316 a wound thereon and a second beam 314 bwith second elastic strands 316 b wound thereon. The first beam 314 a isrotatable about a first beam rotation axis 346 a, and the second beam314 b is rotatable about a second beam rotation axis 346 b. Duringoperation, as the first beam 314 a rotates, the first elastic strands316 a advance in the machine direction MD from the first beam 314 a at aspeed S2 with the first elastic strands 316 a being spaced apart fromeach other in the cross direction CD. From the first beam 314 a, thefirst elastic strands 316 a advance in the machine direction MD and arejoined with the first substrate 306 and the second substrate 308 asdiscussed above. Similarly, as the second beam 314 b rotates, the secondelastic strands 316 b advance in the machine direction MD from thesecond beam 314 b at a speed S3 with the second elastic strands 316 bbeing spaced apart from each other in the cross direction CD. From thesecond beam 314 b, the second elastic strands 316 b advance in themachine direction MD and are joined with the first substrate 306 and thesecond substrate 308 as discussed above. It is also to be appreciatedthat the apparatus configuration shown in FIGS. 10 and 11 may alsoinclude the bond applicator 348 arranged to apply the bonds 322 asdiscussed above. The bond applicator 348 is generically represented by adashed-line rectangle in FIG. 10 .

With continued reference to FIGS. 10 and 11 , the elastic strands 316 a,316 b may be joined with the first and second substrates 306, 308 suchthat the elastomeric laminate 302 may have different stretchcharacteristics in different regions along the cross direction CD. Forexample, when the elastomeric laminate 302 is elongated, the firstelastic strands 316 a may exert contraction forces in the machinedirection MD that are different from contraction forces exerted by thesecond elastic strands 316 b. Such differential stretch characteristicscan be achieved by stretching the first elastic strands 316 a more orless than the second elastic strands 316 b before joining the elasticstrands 316 a, 316 b with the first and second substrates 306, 308. Forexample, as previously discussed, the first substrate 306 and the secondsubstrate 308 may each advance at a speed S1. In some configurations,the first elastic strands 316 a may advance from the first beam 314 a atspeed S2 that is less than the speed S1, and second elastic strands 316b may advance from the second beam 314 b at the speed S3 that is lessthan the speed S1. As such, the first elastic strands 316 a and thesecond elastic strands 316 b are stretched in the machine direction MDwhen combined with the first and second substrates 306, 308. Inaddition, the speed S2 may be less than or greater than different thanthe speed S3. Thus, the first elastic strands 316 a may be stretchedmore or less than the second elastic strands 316 b when combined withthe first and second substrates 306, 308. It is also appreciated thatthe first and second elastic strands 316 a, 316 b may have variousdifferent material constructions and/or decitex values to createelastomeric laminates 302 having different stretch characteristics indifferent regions. In some configurations, the elastic laminate may haveregions where the elastic strands 316 are spaced relatively close to oneanother in the cross direction CD and other regions where the elasticstrands 316 are spaced relatively farther apart from each other in thecross direction CD to create different stretch characteristics indifferent regions. In some configurations, the elastic strands 316 maybe supplied on the beam 314 in a stretched state, and as such, may notrequire additional stretching (or may require relatively less additionalstretching) before being combined with the first substrate 306 and/orthe second substrate 308. Thus, in some configurations, the firstelastic strands 316 a may be supplied on the first beam 314 a at a firsttension, and the second elastic strands 316 b may be supplied on thesecond beam 314 b at a second tension, wherein the first tension is notequal to the second tension.

In another configuration shown in FIG. 12 , the second roller 330 may bepositioned downstream from the first roller 324. As such, the firstroller 324 may be configured as the second metering device 312 and thesecond roller 330 may be configured as a third metering device 366. Asshown in FIG. 14 , the first substrate 306 advances at speed S1 to thefirst roller 324 where the first substrate 306 partially wraps aroundthe outer circumferential surface 326 of the first roller 324 andadvances from the first roller to the second roller 330 to be combinedwith second substrate 308. As the beam 314 rotates, the elastic strands316 advance from the beam 314 at a speed S2 with the elastic strands 316being spaced apart from each other in the cross direction CD. From thebeam 314, elastic strands 316 advance to the first roller 324 and arepositioned on the second surface 340 of the first substrate 306. In someconfigurations, the speed S2 is less than the speed S1, and as such, theelastic strands 316 are stretched in the machine direction MD. Withcontinued reference to FIG. 12 , the first substrate 306 and the elasticstrands 316 advance from the outer circumferential surface 326 of thefirst roller 324 to the second roller 330. In addition, the secondsubstrate 308 advances at speed S1 to the second roller 330 where thesecond substrate 308 partially wraps around the outer circumferentialsurface 332 of the second roller 330. In turn, the combined firstsubstrate 306 and the stretched elastic strands 316 advance from firstroller 324 to the second roller 330 and are combined with the secondsubstrate 308 such that the elastic strands 316 are joined with thesecond surface 340 of the first substrate 306 and the first surface 342of the second substrate 308 to produce a continuous length ofelastomeric laminate 302.

In another configuration shown in FIG. 13 , the apparatus 300 may beconfigured with only the first roller 324 and without a second roller330. As such, the first roller 324 may be configured as the secondmetering device 312. In addition, the first roller 324 may also beconfigured as a component of the bond applicator 348. As shown in FIG.13 , the first substrate 306 advances at speed S1 to the first roller324 where the first substrate 306 partially wraps around the outercircumferential surface 326 of the first roller 324. While partiallywrapped around the outer circumferential surface 326 of the first roller324, the first substrate 306 is combined with the elastic strands 316and the second substrate 308. As the beam 314 rotates, the elasticstrands 316 advance from the beam 314 at a speed S2 with the elasticstrands 316 being spaced apart from each other in the cross directionCD. From the beam 314, elastic strands 316 advance to the first roller324 and are positioned on the second surface 340 of the first substrate306. In some configurations, the speed S2 is less than the speed S1, andas such, the elastic strands 316 are stretched in the machine directionMD. With continued reference to FIG. 13 , the second substrate 308advances at speed S1 to the first roller 324 and partially wraps aroundthe outer circumferential surface 326 of the first roller 324. In turn,the second substrate 308 is combined with the first substrate 306 andthe stretched elastic strands 316 while on the first roller 324 suchthat the elastic strands 316 are joined with the second surface 340 ofthe first substrate 306 and the first surface 342 of the secondsubstrate 308 to produce a continuous length of elastomeric laminate302. In addition, the bond applicator 348 may be configured to apply thebonds 322 before elastic laminate 302 advances from the first roller324.

In some configurations, the speed S2 is less than the speed S1, and assuch, the elastic strands 316 are stretched in the machine direction MD.With continued reference to FIG. 13 , the second substrate 308 advancesat speed S1 to the first roller 324 and partially wraps around the outercircumferential surface 326 of the first roller 324. In turn, the secondsubstrate 308 is combined with the first substrate 306 and the stretchedelastic strands 316 while on the first roller 324 such that the elasticstrands 316 are joined with the second surface 340 of the firstsubstrate 306 and the first surface 342 of the second substrate 308 toproduce a continuous length of elastomeric laminate 302. In addition,the bond applicator 348 may be configured to apply the bonds 322 beforeelastic laminate 302 advances from the first roller 324.

It is also to be appreciated that in some configurations, the firstsubstrate and second substrate 306, 308 herein may be defined by twodiscrete substrates or may be defined by folded portions of a singlesubstrate. For example, as shown in FIG. 14 , the first substrate 306advances at speed S1 to the first roller 324 where the first substrate306 partially wraps around the outer circumferential surface 326 of thefirst roller 324. While partially wrapped around the outercircumferential surface 326 of the first roller 324, the first substrate306 is combined with the elastic strands 316. As the beam 314 rotates,the elastic strands 316 advance from the beam 314 at a speed S2 with theelastic strands 316 being spaced apart from each other in the crossdirection CD. From the beam 314, elastic strands 316 advance to thefirst roller 324 and are positioned on the second surface 340 of thefirst substrate 306. As shown in FIGS. 14 and 15 , a folding device 368may operate to fold a first portion 306 a onto a second portion 306 b ofthe first substrate with the elastic strands 316 positioned between thefirst and second portions 306 a, 306 b to create the elastic laminate302. As shown in FIGS. 14 and 16 , the bond applicator 348 may beconfigured to apply the bonds 322 before elastic laminate 302 advancesfrom the first roller 324.

As illustrated herein, the apparatuses and processes may be configuredsuch that elastic strands may be advanced from the beams and directly tothe assembly process without having to touch additional machinecomponents, such as for example, guide rollers. It is also to beappreciated that in some configurations, elastic strands may be advancedfrom beams and may be redirected and/or otherwise touched by and/orredirected before advancing to the assembly process. For example, FIG.17 shows a configuration where the beam rotation axis 346 may extend ina first cross direction CD1. As the beam 314 rotates, the elasticstrands 316 advance from the beam 314 in a first machine direction MD1with the elastic strands 316 being spaced apart from each other in thefirst cross direction CD1. The elastic strands 316 may then beredirected by rollers 323 from the first machine direction MD1 to asecond machine direction MD2, wherein the elastic strands 316 may remainseparated from each other in a second cross direction CD2. From therollers 323, the elastic strands 316 may advance in the second machinedirection MD2 to be combined with the first and second substrates 306,308 to form the elastomeric laminate 302. Thus, it is to be appreciatedthat the beam 314 may be arranged and/or oriented such that the beamrotation axis 346 may be parallel, perpendicular, or otherwise angularlyoffset with respect to the machine direction advancement of theelastomeric laminate 302 and/or the substrates 306, 308.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application and any patent application or patent to which thisapplication claims priority or benefit thereof, is hereby incorporatedherein by reference in its entirety unless expressly excluded orotherwise limited. The citation of any document is not an admission thatit is prior art with respect to any invention disclosed or claimedherein or that it alone, or in any combination with any other referenceor references, teaches, suggests or discloses any such invention.Further, to the extent that any meaning or definition of a term in thisdocument conflicts with any meaning or definition of the same term in adocument incorporated by reference, the meaning or definition assignedto that term in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A method for making an elastomeric laminate, themethod comprising steps of: providing an elastic strand, wherein theelastic strand defines a first cross sectional area in an unstretchedstate; stretching the elastic strand, wherein the stretched elasticstrand defines a second cross sectional area that is less than the firstcross sectional area; advancing a first substrate and a second substratewith the stretched elastic strand between the first substrate and thesecond substrate; applying heat and pressure to a first region of thefirst substrate and a second region of the second substrate by advancingthe first substrate, the second substrate, and the stretched elasticstrand between a pattern surface and an ultrasonic horn, wherein thepattern surface extends contiguously at relatively high and lowelevations across the stretched elastic strand and the first and secondsubstrates, such that malleable first material of the first substrateand malleable second material of the second substrate deform tocompletely surround an outer perimeter of the stretched elastic strand,and removing heat and pressure from the first region of the firstsubstrate and the second region of the second substrate to allow themalleable first material and the malleable second material to harden andconforming with a cross sectional shape defined by the outer perimeterof the stretched elastic strand and to form a bond having varyingthicknesses; and applying a frictional lock between a portion of theelastic strand and the hardened first and second materials by releasingtension from the stretched elastic strand.
 2. The method of claim 1,wherein the bond does not include adhesive.
 3. The method of claim 1,further comprising unwinding the elastic strand from a beam.
 4. Themethod of claim 3, wherein the step of stretching is performedsubsequent to the step of unwinding.
 5. The method of claim 1, whereinthe elastic strand comprises a filament, and wherein the bond defines athickness that is at least 50% greater than a minimum cross sectionalthickness of the filament.
 6. The method of claim 1, wherein the elasticstrand comprises a spin finish.
 7. The method of claim 6, furthercomprising a step of removing a portion of the spin finish.
 8. Themethod of claim 1, wherein the first substrate comprises a firstnonwoven and the second substrate comprises a second nonwoven.
 9. Themethod of claim 1, wherein the elastic strand comprises a decitex ofless than about
 100. 10. The method of claim 1, further comprising stepsof: providing a substrate; and folding a first portion of the substrateonto a second portion of the substrate, wherein the first portiondefines the first substrate and wherein the second portion defines thesecond substrate.
 11. A method for making an elastomeric laminate, themethod comprising steps of: positioning an elastic strand between afirst substrate and a second substrate, the elastic strand comprising anouter perimeter; stretching the elastic strand; advancing the firstsubstrate, the second substrate, and the stretched elastic strandbetween a pattern surface and an ultrasonic horn, wherein the patternsurface extends contiguously at relatively high and low elevationsacross the stretched elastic strand and the first and second substrates;heating a first region of the first substrate and a second region of thesecond substrate such that first material of the first substrate andsecond material of the second substrate become malleable; and applyingpressure to the first region, the second region, and the stretchedelastic strand together such that the malleable first material of thefirst substrate and the malleable second material of the secondsubstrate deform to completely surround the outer perimeter of thestretched elastic strand, and removing pressure from the first region,the second region, and the stretched elastic strand to allow themalleable first material and the malleable second material to harden ina cross sectional shape conforming with a cross sectional shape definedby the outer perimeter of the stretched elastic strand and to form abond having varying thicknesses; and applying a frictional lock betweena discrete length of the elastic strand and the hardened first andsecond materials by releasing tension from the stretched elastic strand.12. The method of claim 11, further comprising the step of stretchingthe elastic strand prior to the step of positioning the elastic strandbetween the first substrate and the second substrate.
 13. The method ofclaim 12, further comprising unwinding the elastic strand from a beam.14. The method of claim 13, wherein step of stretching is performedsubsequent to the step of unwinding.
 15. The method of claim 11, whereinno adhesive is present between the stretched elastic strand and thehardened first and second materials.
 16. The method of claim 11, whereinthe elastic strand comprises a filament, and wherein the hardened firstand second materials defines a thickness that is at least 50% greaterthan a minimum cross sectional thickness of the filament.
 17. A methodfor making an elastomeric laminate, the method comprising steps of:providing an elastic strand, wherein the elastic strand defines a firstcross sectional area in an unstretched state; stretching the elasticstrand, wherein the stretched elastic strand defines a second crosssectional area that is less than the first cross sectional area;providing a substrate comprising a first surface and an opposing secondsurface; positioning the stretched elastic stand on the first surface ofthe substrate; folding a first portion of the substrate onto a secondportion of the substrate with the stretched elastic strand positionedbetween the first portion and the second portion of the substrate;applying heat and pressure to a first region of the first portion and asecond region of the second portion by advancing the substrate and thestretched elastic strand between a pattern surface and an ultrasonichorn, wherein the pattern surface extends contiguously at relativelyhigh and low elevations across the elastic strand and the substrate,such that malleable material of the substrate deform to completelysurround an outer perimeter of the stretched elastic strand, andremoving heat and pressure from the first region and the second regionto allow the malleable material to harden to define a cross sectionalshape conforming with a cross sectional shape defined by the outerperimeter of the stretched elastic strand and to form a bond havingvarying thicknesses; and applying a frictional lock between a portion ofthe elastic strand and the hardened malleable material by releasingtension from the stretched elastic strand.
 18. The method of claim 17,wherein no adhesive is present between the hardened malleable materialand the elastic strand.
 19. The method of claim 17, further comprisingunwinding the elastic strand from a beam.
 20. The method of claim 19,wherein the step of stretching is performed subsequent to the step ofunwinding.
 21. The method of claim 17, further comprising unwinding theelastic strand from a single roll with a rolling unwind.
 22. The methodof claim 17, wherein the elastic strand comprises a filament, andwherein the hardened malleable material defines a thickness that is atleast 50% greater than a minimum cross sectional thickness of thefilament.